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Old 10-13-2011, 04:00 AM   #1
alamike's Avatar
Join Date: Dec 2010
Location: Grass Valley, California
Posts: 60
Battery cables with welding wire?

1997 Wrangler, Sahara edition, 4.0L.

My battery cables are shot and the jeep dealership in the closest town wants $100 for a set. I've got some wire laying around for my Lincoln MIG welder and read somewhere that you could make a set using this welding wire and a few pieces from the hardware store. Could anyone explain if this is possible and how to do it? I need to replace all of it: terminals, the connector to the starter and fuse box, ground, etc. Thanks guys!

'97 Sahara TJ
-4.0L manual on 35's
-4" Teraflex lift, 4.56 gears
-Dana 30 w/ OX locker up front, Dana 35 w/Detroit in the rear (for now)
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Old 10-13-2011, 07:12 AM   #2
Join Date: Sep 2011
Location: Delaware
Posts: 178
I have never made up cables for my jeep, but have done this in the past with other vehicles. The hardest part for you would be finding the right ends and having access to the crimper needed to put them on properly.

This guy makes a killer set, a little more than $100, but SO much better than stock..
Jeep Wrangler cables

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Old 10-13-2011, 07:15 AM   #3
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Auto part store less then 50$.
93 YJ I6 5spd
My YJ Build +1.5 inch SOA ,37 12.50 15R Swamper M16's, 5.22:1/2.97:1 Stak Tcase with 92 Crawl Ratio--------SOLD...
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Old 10-13-2011, 07:35 AM   #4
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Location: Garland
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I did this on my 2001 Cherokee. Real easy. Take the measurement of each cable

Battery to Starter
Battery to Power Distribution Center
Alternator to Power Distribution Center
Alternator to Battery

Battery to Chassis Ground
Battery to Block Ground
Block to Firewall Ground (Crappy metal mesh wire at the back of the engine)

2 Marine Terminal to attach to the battery (They have wing nut post for attaching the the cables.

Measure the Size of the bolts at the Chassis, PDC, Starter, Engine Block (Both side and back ground connections), and Fire Wall.

Take measurements and corrorsponding bolt sizes down to your local welding supply store. Have them make the measure lengths of cable and attach the appropriate size ends and crimp them.

Get some colored heat shrink tubing to place over the ends of the positive cables for easy identification.

You also need a In-line fuse between the alternator and the PDC. The fuse needs to be rated close to the max output of your alt to prevent too much amprage going into the PDC.

Hook it all up and have a ball.
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Old 10-13-2011, 07:38 AM   #5
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Or you can solder the ends on, or that's what I did to all of em on my golf cart
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Old 10-13-2011, 10:13 AM   #6
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Location: San Diego
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I would use at least 6 gauge. If I did it on my jeep i'd probably use 0 gauge. Welding wire is usually very high quality wire, just be sure that it's the right gauge.
my 06 LJ rubicon
2.5" SL, 1" BL, DIY highline, 35s with double beadlocks.
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Old 10-13-2011, 11:41 AM   #7
Knows a couple things...

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Location: Escondido, Calif.
Posts: 38,526
Yep welding wire is usually fine-strand copper cable which is higher quality than typical battery cables. No problem using that if you use the right gauge of wiring. I'd probably go for 2 gauge.

When you have a choice, buy American.

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